Elise - retirement project

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stratosboy
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Elise - retirement project

Post by stratosboy » Tue Oct 10, 2017 8:07 pm

So after 35 years service in the NHS, mental health care, I need something to fiddle with!. - especially as Zetec Elan project is sold.
Therefore decided on an S1 Elise rebuild project (with a difference!).
bought a nice 99 Azure blue one in the summer, a lovely thing, but high mileage and in need of a refresh. Great drive home with it though, ran well. I've never driven one before and really liked it.
July 2017 234.JPG
July 2017 234.JPG (62.22 KiB) Viewed 2919 times
1st job - strip out and sell off bits I don't need. So seats, wheels, roof, engine/box, induction kit, clams, engine cover, roll bar, shocks, exhaust all sold.
September 2017 002.JPG
September 2017 002.JPG (51.5 KiB) Viewed 2919 times

(I have some bits still available: ECU, aluminium uprights, drive shafts, brake discs, various trim bits, CAT, roll hoop cover, radiator, fuel pump)

new motorsport clams, roof, engine cover and spoiler to go on:
Lotus Elise 013.JPG
Lotus Elise 013.JPG (57.45 KiB) Viewed 2919 times
September 2017 013.JPG
2nd job - fit 6 point roll cage, tricky but pleased with it:
September 2017 043.JPG
September 2017 043.JPG (54.63 KiB) Viewed 2919 times
more to follow....
Last edited by stratosboy on Wed Oct 18, 2017 7:42 pm, edited 4 times in total.
Exige S - V6
Audi 20v turbo Elise Motorsport replica project

stratosboy
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Re: Elise - retirement project

Post by stratosboy » Tue Oct 10, 2017 8:10 pm

mmmm don't know why my pics are not happening. I'll try again later.
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Audi 20v turbo Elise Motorsport replica project

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mill
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Re: Elise - retirement project

Post by mill » Tue Oct 10, 2017 9:58 pm

Can’t see the pics but sounds like it’ll be some weapon! :jaw:
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whitergb
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Re: Elise - retirement project

Post by whitergb » Tue Oct 10, 2017 10:01 pm

7th job - fit traction control to keep it on the black stuff!
Elise SC RGB Edition Aspen White
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stratosboy
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Re: Elise - retirement project

Post by stratosboy » Wed Oct 18, 2017 8:02 pm

3rd job - suspension refresh:
Elise suspension refresh parts.png
Elise suspension refresh parts.png (168.56 KiB) Viewed 2919 times
Elise front suspension rebuild.png
Elise front suspension rebuild.png (271.33 KiB) Viewed 2919 times
4th job - engine build: - I'm going with a charge cooled VAG 1.8turbo (although stroked to 2.0l) with big turbo installation. 6 speed box.
baffled sump -
Elise stripdown August 2017 112.JPG
Elise stripdown August 2017 112.JPG (87.24 KiB) Viewed 2919 times
modified inlet manifold -
Elise stripdown August 2017 125.JPG
Elise stripdown August 2017 125.JPG (58.02 KiB) Viewed 2919 times
charge cooler -
Elise stripdown August 2017 133.JPG
Elise stripdown August 2017 133.JPG (74.19 KiB) Viewed 2919 times


more to come....
Exige S - V6
Audi 20v turbo Elise Motorsport replica project

stratosboy
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Re: Elise - retirement project

Post by stratosboy » Wed Oct 18, 2017 8:10 pm

5th job brakes: I've got new 308 discs all round, front AP calipers are going on the rear, with spot calipers for handbrake. Caparo 4 pot calipers up front. New larger bore master cylinder fitted for 4 pots.
pics to follow.

6th job cooling: new Pro Alloy 3 pass radiator, with twin fans, and Pro Alloy charge cooler rad to go in. Silicone hoses all round -
Elise stripdown August 2017 120.JPG
Elise stripdown August 2017 120.JPG (47.5 KiB) Viewed 2919 times
Elise stripdown August 2017 138.JPG
Elise stripdown August 2017 138.JPG (71.67 KiB) Viewed 2919 times


7th job traction control to keep it on the black stuff!

some other bits to go in: Tilletts -
Elise stripdown August 2017 148.JPG
Elise stripdown August 2017 148.JPG (76.61 KiB) Viewed 2919 times
coolant tanks for fitting onto bulkhead where rear window used to be -
Elise stripdown August 2017 135.JPG
Elise stripdown August 2017 135.JPG (66.93 KiB) Viewed 2919 times
more to follow...
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Audi 20v turbo Elise Motorsport replica project

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Nathan
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Re: Elise - retirement project

Post by Nathan » Thu Oct 19, 2017 5:07 am

Wow! Sounds like a great project, hope some day I’ve got the time/money/space to start a project like this. Well done, keep the posts coming!
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stratosboy
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Re: Elise - retirement project

Post by stratosboy » Sun Oct 22, 2017 1:19 pm

some more progress, first trial fit of body panels, lots of fettling yet to get them right, but I like this bit
suspension fitted too: :Diablo:
elise 2.png
elise 2.png (147.26 KiB) Viewed 2870 times
Elise 1.png
Elise 1.png (141.58 KiB) Viewed 2870 times
Elise build Ocr 2017.png
Elise build Ocr 2017.png (153.84 KiB) Viewed 2870 times
elise 3.png
elise 3.png (134.49 KiB) Viewed 2870 times
Exige S - V6
Audi 20v turbo Elise Motorsport replica project

stratosboy
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Re: Elise - retirement project

Post by stratosboy » Sun Oct 29, 2017 7:45 pm

a few more jobs done:
original Stack readouts are not that good, so added some extra Stack gauges where the radio and heater used to live:
Stack Dials 2017 004.JPG
Stack Dials 2017 004.JPG (54.18 KiB) Viewed 2811 times
Stack Dials 2017 002.JPG
Stack Dials 2017 002.JPG (52.35 KiB) Viewed 2811 times
Stack Dials 2017 003.JPG
Stack Dials 2017 003.JPG (54.36 KiB) Viewed 2811 times
and drive shaft build up under way:
Stack Dials 2017 005.JPG
Stack Dials 2017 005.JPG (53.72 KiB) Viewed 2811 times
Exige S - V6
Audi 20v turbo Elise Motorsport replica project

stratosboy
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Re: Elise - retirement project

Post by stratosboy » Sun Oct 29, 2017 7:51 pm

6 speed VAG gearbox, cleaned and ready to go on when engine returns from builders:
Elise stripdown August 2017 137.JPG
Elise stripdown August 2017 137.JPG (79.62 KiB) Viewed 2810 times
and 60L Pro Alloy fuel tank with central collector fitted this weekend:
Elise stripdown August 2017 140.JPG
Elise stripdown August 2017 140.JPG (41.66 KiB) Viewed 2810 times
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Audi 20v turbo Elise Motorsport replica project

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whitergb
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Re: Elise - retirement project

Post by whitergb » Mon Oct 30, 2017 8:59 pm

Looks great, keep the posts coming.
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stratosboy
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Re: Elise - retirement project

Post by stratosboy » Sat Nov 11, 2017 5:50 pm

bit more progress today, Pro Alloy triple pass radiator and charge cooler radiator fitted:
Elise build Nov 2017 011.JPG
Elise build Nov 2017 011.JPG (44.7 KiB) Viewed 2551 times
Elise build Nov 2017 014.JPG
Elise build Nov 2017 014.JPG (85.94 KiB) Viewed 2551 times
Elise build Nov 2017 013.JPG
Elise build Nov 2017 013.JPG (72.05 KiB) Viewed 2551 times
needed a couple of minor mods to radiator shroud, to make it all fit.
Brake master cylinder is larger bore, for use with 4 pot calipers at front.

Drive shafts finished now and ready to go in,
Engine is being rebuilt, and due back in a few weeks

I'll post more when engine is being installed and new mounts fitted.
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Thommo
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Re: Elise - retirement project

Post by Thommo » Sun Nov 19, 2017 9:57 pm

More, please!
Just over the hill

stratosboy
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Re: Elise - retirement project

Post by stratosboy » Mon Nov 20, 2017 10:14 pm

ok, some small bodywork developments this weekend, lights and mesh fitted:
IMG_7014.jpg
IMG_7018.jpg
IMG_7018.jpg (29.6 KiB) Viewed 2372 times
IMG_7015.jpg
IMG_7015.jpg (25.55 KiB) Viewed 2372 times
IMG_7022.jpg
IMG_7022.jpg (23.36 KiB) Viewed 2372 times
IMG_7026.jpg
IMG_7026.jpg (23.51 KiB) Viewed 2372 times


Colour is going to be Porsche Miami blue....I know, it shouldn't have anything Porsche related at all, but it is a fantastic colour.

Carbon engine cover coming this week, will post some pics when I've cut he louvre's out.
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Audi 20v turbo Elise Motorsport replica project

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whitergb
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Re: Elise - retirement project

Post by whitergb » Tue Nov 21, 2017 8:05 am

This is shaping up nicely, what do you envisage the performance figures to be?

Good choice of colour👍
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stratosboy
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Re: Elise - retirement project

Post by stratosboy » Tue Nov 21, 2017 6:57 pm

Thanks,
I'm hoping it will be quite quick! - my engine builder is aiming for 500bhp. but for it to be as driveable on the road, as possible. They are a VAG engine build specialist and have experience of getting over 1000 bhp from the 20v engine. I'll be using it mainly as a road car.

I don't know if you can see from the clam pics, but the clams are wider than stock S1 Exige, by 50 mm each side at the rear and 20 mm each side at the front. This will enable wider wheel fitment. I'm looking to fit 18 x 10 rears and 17 x 9 fronts.

I picked these up today:
Scroth Harnesses.png
Scroth Harnesses.png (250.76 KiB) Viewed 2343 times
and need some advice for their fitment to Tillett B5 seats. (I have Tilletts online guide) - I'd like to keep the OEM seatbelts for convenience. So want to fit these too. Has anyone done this and can help with some advice? - I have Tillett's EB1 seat brackets, and not using the original seat runners. Cheers Dave
Exige S - V6
Audi 20v turbo Elise Motorsport replica project

stratosboy
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Re: Elise - retirement project

Post by stratosboy » Mon Jan 08, 2018 5:23 pm

some progress over Christmas/New year, rear discs and brakes built up and trial fitted:
elise AP discs.jpg
elise discs rear 3.jpg
elise brakes rear 2.jpg
elise brakes rear.jpg
needs a bit of fettling yet, caliper is very tight fit, needs shimming outwards slightly.
these are 308mm AP discs.
Exige S - V6
Audi 20v turbo Elise Motorsport replica project

stratosboy
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Re: Elise - retirement project

Post by stratosboy » Tue Jan 09, 2018 1:24 pm

oops! did you spot that I've fitted my first disc (rear) on the wrong side?
corrected at the front:
elise brakes front.jpg
left:
elise brakes front left 3.jpg
elise brakes front left 1.jpg
right:
elise brakes front right 1.jpg
elise brakes front right 3.jpg
elise brakes front right 4.jpg
Exige S - V6
Audi 20v turbo Elise Motorsport replica project

stratosboy
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Re: Elise - retirement project

Post by stratosboy » Sat Jan 13, 2018 10:42 pm

good day in garage today, cut out the number plate recess to aid hot air venting. I will mesh behind to add some more strength back
The attachment rear clam.jpg is no longer available
fitted new longerons:
The attachment new longerons 3.jpg is no longer available
The attachment new longerons 2.jpg is no longer available
and then the rear clam quick release kit:
The attachment rear clam quick release kit 3.jpg is no longer available
rear clam.jpg
The attachment rear clam quick release kit 6.jpg is no longer available
Exige S - V6
Audi 20v turbo Elise Motorsport replica project

stratosboy
Posts: 199
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Re: Elise - retirement project

Post by stratosboy » Sun Jan 14, 2018 2:32 pm

having problems posting pics on here....will keep trying.
New longerons fitted:
The attachment new longerons 2.jpg is no longer available
The attachment new longerons 3.jpg is no longer available
new longerons 2.jpg
and yes I know I have some goggly eyes looking at me out of the subframe!!
Exige S - V6
Audi 20v turbo Elise Motorsport replica project

stratosboy
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Re: Elise - retirement project

Post by stratosboy » Sun Jan 14, 2018 2:34 pm

seems to be only letting me post one pic each time:
here's the quick release runners fitted on top of the new longerons:
rear clam quick release kit 6.jpg
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Audi 20v turbo Elise Motorsport replica project

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nelly111s
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Re: Elise - retirement project

Post by nelly111s » Sun Jan 14, 2018 7:05 pm

I've tried altering the settings - it should let you post 6 pictures per post, so you could try again.It's maybe another limit somewhere that I reset by mistake in the forum rebuild.

Nelly
Silver 111S - gone
Ardent Red 111R - gone
Chrome Orange S - yippee

stratosboy
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Re: Elise - retirement project

Post by stratosboy » Sun Jan 14, 2018 7:31 pm

cheers Nelly, seems to have fixed it.
so more of the longerons and quick release kit:
The attachment new longeron side.png is no longer available
The attachment new longeron R.png is no longer available
The attachment new longeron.png is no longer available
quick release runners:
The attachment quick release kit 3.png is no longer available
The attachment rear clam quick release kit 7.png is no longer available
new longeron side.png
got cut to pieces fitting these yesterday, the edges of the longerons are incredibly sharp, I kept wondering where all the blood was coming from!
Exige S - V6
Audi 20v turbo Elise Motorsport replica project

stratosboy
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Re: Elise - retirement project

Post by stratosboy » Sun Jan 14, 2018 7:32 pm

oops no it hasn't...looked ok in the preview, but still not allowing more than one pic through!
Exige S - V6
Audi 20v turbo Elise Motorsport replica project

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nelly111s
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Re: Elise - retirement project

Post by nelly111s » Mon Jan 15, 2018 10:05 pm

It might be the size of the images. They look like they're about 12MB and 4000x3000. Try reducing the size (to about 3 or 4 MB) by either reducing the dimensions or compression. Try a 2000 wide setting and see if you can post more then.

Nelly
Silver 111S - gone
Ardent Red 111R - gone
Chrome Orange S - yippee

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